SUPPLEMENT TO CHAPTER 15:
Maintenance is critical with JIT and TQM implementation. Poor maintenance leads to direct repair
expenses and other expenses resulting from lost production. The production line disruptions are
particularly important in JIT environments. An effective maintenance program ensures that machines are
functioning and performing the operations so that quality of the product is not compromised. An effective
maintenance program can lead to improved capacity, reduction in defects, scrap and rework, smaller
inventories, higher productivity and lower product costs.
Answers to Discussion and Review Questions
The goal of a maintenance program is to minimize the total cost of keeping
facilities and equipment in good working order.
Breakdown costs would include such items as repair of equipment (perhaps on an
emergency basis), lost production, disrupted schedules, parts, possible damage to product,
equipment, and facilities, possible injuries, late deliveries, and loss of morale.
Preventive maintenance may result from inspections that reveal the need for
preventive maintenance, according to calendar (passage of time), or after a set number of
Predictive maintenance is an attempt to predict when breakdowns are likely and
schedule preventive maintenance just prior to that time. Generally, such predictions are
made on the basis of historical breakdown and repair records. Consequently, it is essential
to have accurate, up-to-date records on which to base the analysis.
Organizations use some combination of these approaches to deal with
breakdowns: Standby or backup equipment; inventories of spare parts; reliance on
operators to perform some (usually minor) repairs; and well-trained repair personnel.
The Pareto concept is that in any list of factors known to contribute to a certain
result or outcome (accident, injury, equipment breakdown or whatever), a relatively few
factors will account for a disproportionate share of the result (e.g., 90% of accidents are
caused by carelessness). The importance of this is that maintenance efforts (both
preventative and remedial) will be most effective when they are directed towards those few
factors (procedures, equipment, policies, or whatever) that are most significant, and give
much less attention to minor factors.
The key points should involve these concepts:
The need for maintenance
Operations Management, 9/e